I have 2 projects that had no problems until I added
variables. Now they crash about 90% of the time while generating
the .chm file, and always during the "updating" stage. (Eventually,
I do manage...)

I am using RoboHelp 7, and not on a server. I have tried
replacing the CPD file.

Variables as such are not known to cause projects to crash
and the fact that you do manage to get the project to generate
means the problem is not in this area. Are you generating to a
server? If you are, try generating to a local drive and see if that
helps. If not, have you access to another PC that you could test
this on?

Thanks for the quick response.
I only assumed that the problem was caused by the variables,
because I didn't have problems until I added the variables.
The files are being generated to my local computer. I have
copied the whole project to my second computer, and the same thing
happens.

I have tried looking at the error report, but don't
understand anything. Would you like to see it?

Can't remember if we tried this with your other post on this
issue but did you create a new project and import in one of your
variable files. Don't add a variable to a topic. Does this project
generate? If so, add a single variable to a topic and generate
again. If this works, add another variable and generate. Repeat
until he hit a problem and report back.

Also, today I tried generating a Word document, and the same
thing happened - RH crashed a few times while updating. (Problem
was solved when I generated the document with the images in a
linked file.)